U.S. patent application number 11/057768 was filed with the patent office on 2006-08-17 for goalie skate.
This patent application is currently assigned to BAUER NIKE Hockey Inc.. Invention is credited to Ivan Labonte.
Application Number | 20060181035 11/057768 |
Document ID | / |
Family ID | 36814892 |
Filed Date | 2006-08-17 |
United States Patent
Application |
20060181035 |
Kind Code |
A1 |
Labonte; Ivan |
August 17, 2006 |
Goalie skate
Abstract
A goalie skate having a skate boot comprising a thermoformed
outer shell with a sole and an ankle portion for receiving the
ankle of the foot, the ankle portion comprising medial and lateral
sides for facing the medial and lateral malleoli respectively, the
medial side comprising an upper edge that is a first distance away
from the sole and the lateral side comprising an upper edge that is
a second distance away from the sole, the first distance being
greater than the second distance. By having a goalie skate boot
that has the lateral upper edge located below the medial upper
edge, the lateral outward flexion of the foot is eased when the
goalie skate is in an angled position. The invention also relates
to a goalie skate with a skate boot comprising an outer shell that
is thermoformed such that it comprises an integrated toe portion,
thereby eliminating the traditional toe cap.
Inventors: |
Labonte; Ivan; (Montreal,
CA) |
Correspondence
Address: |
FETHERSTONHAUGH - SMART & BIGGAR
1000 DE LA GAUCHETIERE WEST
SUITE 3300
MONTREAL
QC
H3B 4W5
CA
|
Assignee: |
BAUER NIKE Hockey Inc.
|
Family ID: |
36814892 |
Appl. No.: |
11/057768 |
Filed: |
February 15, 2005 |
Current U.S.
Class: |
280/11.12 |
Current CPC
Class: |
B29D 35/0054 20130101;
B29D 35/126 20130101; A43B 5/1666 20130101 |
Class at
Publication: |
280/011.12 |
International
Class: |
A63C 1/00 20060101
A63C001/00 |
Claims
1. A goalie skate for enclosing a human foot, the foot having a
heel, an ankle with a medial malleolus and a lateral malleolus,
medial and lateral sides, a plantar surface and toes, said goalie
skate comprising: (a) a skate boot comprising an outer shell made
of a thermoformable material, said outer shell being thermoformed
such that it comprises: i) a sole for facing the plantar surface of
the foot; ii) a heel portion for receiving the heel of the foot;
iii) medial and lateral side portions for facing the medial and
lateral sides of the foot respectively; and iv) an ankle portion
for receiving the ankle of the foot, said ankle portion comprising
a medial side having an upper edge that is a first distance away
from said sole and a lateral side having an upper edge that is a
second distance away from said sole, said first distance being
greater than said second distance; and (b) a rigid shell comprising
a toe portion for protecting the toes and a bottom portion for
receiving an ice skate blade.
2. A goalie skate as defined in claim 1, wherein said second
distance is at least 5 mm greater than said first distance.
3. A goalie skate as defined in claim 1, wherein said bottom
portion of said rigid shell comprises a base, an ice skate blade
receiving portion and at least one pedestal connecting said base
and said ice skate blade receiving portion.
4. A goalie skate as defined in claim 3, wherein said ice skate
blade receiving portion comprises a longitudinal slot for receiving
said ice skate blade.
5. A goalie skate as defined in claim 3, wherein said rigid shell
comprises medial and lateral walls and a heel portion extending
upwardly from said base, said medial and lateral walls, heel
portion, toe portion and base defining a cavity for receiving at
least partially said skate boot.
6. A goalie skate as defined in claim 5, wherein said rigid shell
is a cowling.
7. A goalie skate as defined in claim 3, wherein said outer shell
is thermoformed such that said heel portion is substantially cup
shaped for following the contour of the heel of the foot.
8. A goalie skate as defined in claim 7, wherein said outer shell
is thermoformed such that said medial and lateral sides comprise
respective medial and lateral cup-shaped depressions for receiving
the medial and lateral malleoili respectively.
9. A goalie skate as defined in claim 8, wherein said lateral
cup-shaped depression is below said medial cup-shaped
depression.
10. A goalie skate as defined in claim 3, wherein said outer shell
is thermoformed such that said medial and lateral side portions
comprise foldable skirt portions projecting therefrom for forming
said sole.
11. A goalie skate as defined in claim 3, wherein said outer shell
is made of a single sheet of thermoformable material.
12. A goalie skate as defined in claim 11, wherein said sheet is a
composite sheet comprising a layer of thermoformable foam.
13. A goalie skate as defined in claim 3, wherein said skate boot
comprises an inner lining having a surface intended for contact
with the heel, ankle and lateral and medial sides of the foot, said
inner lining being affixed to an inner surface of said outer
shell.
14. A goalie skate as defined in claim 3, wherein said skate boot
comprises a footbed adapted for being inserted within said skate
boot.
15. A goalie skate as defined in claim 3, wherein said skate boot
comprises a toe cap and a tongue, said toe cap being affixed to
each of said medial and lateral side portions of said outer
shell.
16. A goalie skate as defined in claim 15, wherein said skate boot
is a lasted skate boot.
17. A goalie skate as defined in claim 3, wherein said medial and
lateral upper edges are located just below the medial and lateral
malleoli respectively.
18. A goalie skate for enclosing a human foot, the foot having a
heel, an ankle with a medial malleolus and a lateral malleolus,
medial and lateral sides, a plantar surface and toes, said goalie
skate having a skate boot comprising an outer shell made of a
thermoformable material, said outer shell being thermoformed such
that it comprises: (a) a heel portion for receiving the heel of the
foot; (b) medial and lateral side portions for facing the medial
and lateral sides of the foot respectively; and (c) an ankle
portion for receiving the ankle of the foot, said ankle portion
comprising a medial side having a medial upper edge and a lateral
side having a medial upper edge, said lateral upper edge being
located below said medial upper edge such that lateral outward
flexion of the foot is eased when said goalie skate is in an angled
position relative to the ground.
19. A goalie skate as defined in claim 18 further comprising a
rigid shell comprising a toe portion for protecting the toes and a
bottom portion for receiving an ice skate blade.
20. A goalie skate as defined in claim 19, wherein said bottom
portion of said rigid shell comprises a base, an ice skate blade
receiving portion and at least one pedestal connecting said base
and said ice skate blade receiving portion.
21. A goalie skate as defined in claim 20, wherein said ice skate
blade receiving portion comprises a longitudinal slot for receiving
said ice skate blade.
22. A goalie skate as defined in claim 20, wherein said rigid shell
comprises medial and lateral walls and a heel portion extending
upwardly from said base, said medial and lateral walls, heel
portion, toe portion and base defining a cavity for receiving at
least partially said skate boot.
23. A goalie skate as defined in claim 22, wherein said rigid shell
is a cowling.
24. A goalie skate as defined in claim 20, wherein said outer shell
is thermoformed such that said heel portion is substantially cup
shaped for following the contour of the heel of the foot.
25. A goalie skate as defined in claim 24, wherein said outer shell
is thermoformed such that said medial and lateral sides comprise
respective medial and lateral cup-shaped depressions for receiving
the medial and lateral malleoili respectively.
26. A goalie skate as defined in claim 25, wherein said lateral
cup-shaped depression is below said medial cup-shaped
depression.
27. A goalie skate as defined in claim 20, wherein said outer shell
is thermoformed such that said medial and lateral side portions
comprise foldable skirt portions projecting therefrom for forming a
sole facing the plantar surface of the foot.
28. A goalie skate as defined in claim 20, wherein said outer shell
is made of a single sheet of thermoformable material.
29. A goalie skate as defined in claim 28, wherein said sheet is a
composite sheet comprising a layer of thermoformable foam.
30. A goalie skate as defined in claim 20, wherein said skate boot
comprises an inner lining having a surface intended for contact
with the heel, ankle and lateral and medial sides of the foot, said
inner lining being affixed to an inner surface of said outer
shell.
31. A goalie skate as defined in claim 20, wherein said skate boot
comprises a footbed adapted for being inserted within said skate
boot.
32. A goalie skate as defined in claim 20, wherein said skate boot
comprises a toe cap and a tongue, said toe cap being affixed to
each of said medial and lateral side portions of said outer
shell.
33. A goalie skate as defined in claim 32, wherein said skate boot
is a lasted skate boot.
34. A goalie skate as defined in claim 20, wherein said medial and
lateral upper edges are located just below the medial and lateral
malleoli respectively.
35. A goalie skate for enclosing a human foot, the foot having a
heel, an ankle with a medial malleolus and a lateral malleolus,
medial and lateral sides, a plantar surface and toes, said goalie
skate comprising: (a) a skate boot comprising an outer shell made
of a thermoformable material, said outer shell being thermoformed
such that it comprises: i) a heel portion for receiving the heel of
the foot; ii) medial and lateral side portions for facing the
medial and lateral sides of the foot respectively; iii) an ankle
portion for receiving the ankle of the foot; iv) a toe portion for
facing the toes of the foot; and v) a sole for facing the plantar
surface of the foot; and (b) a rigid shell comprising a base for
receiving said sole of said outer shell, a toe portion for at least
partially covering said toe portion of said outer shell and a
bottom portion for receiving an ice skate blade.
36. A goalie skate as defined in claim 35, wherein said outer shell
of said skate boot is thermoformed such that said ankle portion
comprises a medial side having a medial upper edge and a lateral
side having a medial upper edge, said lateral upper edge being
located below said medial upper edge such that lateral outward
flexion of the foot is eased when said goalie skate is in an angled
position relative to the ground.
37. A goalie skate as defined in claim 35, wherein said outer shell
of said skate boot is thermoformed such said medial and lateral
side portions comprise foldable skirt portions projecting therefrom
for forming said sole.
38. A goalie skate as defined in claim 37, wherein said ankle
portion comprises a medial side having an upper edge that is a
first distance away from said sole and a lateral side having an
upper edge that is a second distance away from said sole, said
first distance being greater than said second distance.
39. A goalie skate as defined in claim 35, wherein said bottom
portion of said rigid shell comprises an ice skate blade receiving
portion and at least one pedestal connecting said base and said ice
skate blade receiving portion.
40. A goalie skate as defined in claim 39, wherein said ice skate
blade receiving portion comprises a longitudinal slot for receiving
said ice skate blade.
41. A goalie skate as defined in claim 39, wherein said rigid shell
comprises medial and lateral walls and a heel portion extending
upwardly from said base, said medial and lateral walls, heel
portion, toe portion and base defining a cavity for receiving at
least partially said skate boot.
42. A goalie skate as defined in claim 41, wherein said rigid shell
is a cowling.
43. A goalie skate as defined in claim 35, wherein said outer shell
of said skate boot is thermoformed such that said heel portion is
substantially cup shaped for following the contour of the heel of
the foot.
44. A goalie skate as defined in claim 35, wherein said outer shell
of said skate boot is thermoformed such that said medial and
lateral sides comprise respective medial and lateral cup-shaped
depressions for receiving the medial and lateral malleoili
respectively.
45. A goalie skate as defined in claim 44, wherein said lateral
cup-shaped depression is below said medial cup-shaped
depression.
46. A goalie skate as defined in claim 42, wherein said outer shell
of said skate boot is thermoformed such said medial and lateral
side portions comprise foldable skirt portions projecting therefrom
for forming said sole.
47. A goalie skate as defined in claim 46, wherein said ankle
portion comprises a medial side having an upper edge that is a
first distance away from said sole and a lateral side having an
upper edge that is a second distance away from said sole, said
first distance being greater than said second distance.
48. A goalie skate as defined in claim 42, wherein said outer shell
of said skate boot is thermoformed such that said ankle portion
comprises a medial side having a medial upper edge and a lateral
side having a medial upper edge, said lateral upper edge being
located below said medial upper edge such that lateral outward
flexion of the foot is eased when said goalie skate is in an angled
position relative to the ground.
49. A goalie skate as defined in claim 42, wherein said skate boot
comprises an inner lining having a surface intended for contact
with the heel, ankle and lateral and medial sides of the foot, said
inner lining being affixed to an inner surface of said outer
shell.
50. A goalie skate as defined in claim 42, wherein said skate boot
comprises a footbed adapted for being inserted within said skate
boot.
51. A goalie skate as defined in claim 42, wherein said skate boot
comprises a tongue affixed to said toe portion of said outer
shell.
52. A goalie skate as defined in claim 42, wherein said skate boot
is a lasted skate boot.
53. A goalie skate for enclosing a human foot, the foot having a
heel, an ankle with a medial malleolus and a lateral malleolus,
medial and lateral sides, a plantar surface and toes, said goalie
skate comprising: (a) a skate boot comprising an outer shell made
of a thermoformable material, said outer shell being thermoformed
such that it comprises: (i) a heel portion for receiving the heel
of the foot; (ii) medial and lateral side portions for facing the
medial and lateral sides of the foot respectively; said medial and
lateral side portions comprising foldable skirt portions projecting
therefrom for forming a sole for facing the plantar surface of the
foot; and (iii) an ankle portion for receiving the ankle of the
foot, said ankle portion comprising a medial side having a medial
upper edge and a lateral side having a medial upper edge, said
lateral upper edge being located below said medial upper edge such
that lateral outward flexion of the foot is eased when said goalie
skate is in an angled position relative to the ground; and (b) a
rigid shell comprising a toe portion for protecting the toes, a
base for facing said sole of said outer shell, medial and lateral
walls and a heel portion extending upwardly from said base, said
medial and lateral walls, heel portion, toe portion and base
defining a cavity for receiving at least partially said skate boot.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a goalie skate having a
boot made of a thermoformable material.
BACKGROUND OF THE INVENTION
[0002] In hockey, the role of the goalie differs significantly from
the role of the other hockey players. For example, the goalie
spends far more time standing in front of the net than skating
around the ice rink. In addition, the way in which the goalie
stands and moves is quite different from the way the other players
stand and move.
[0003] It is common that during a game of hockey, a goalie might
assume an angled position wherein the goalie's skates are
positioned at oblique angles in relation to the ice surface. In
other words, the goalie stands such that the blades of the skates
are not vertically parallel as they would normally be for a
defenceman or a forward standing at rest. Instead, the goalie's
skates are angled away from the goalie's body thereby widening the
points of contact between the goalie and the ice and bringing the
goalie's knees together.
[0004] Furthermore, goalies are often known to adopt a "butterfly
position" whereby their knees flex and their feet are spread apart
in order to cover as much of the lower portion of the net as
possible.
[0005] A deficiency with existing goalie skates is that they may
cause discomfort to goalies during the course of a game of hockey.
For example, a deficiency with existing goalie skates is that when
the goalie assumes an angled position, the upper edge of the
lateral side of the skate boot may dig into the lateral side of the
goalie's leg. Obviously, this can cause the goalie discomfort, and
can limit the range of movement available to the goalie.
[0006] Accordingly, there is a need in the industry for a goalie
skate that takes into consideration the types of movements
performed by goalies, in order to provide a more comfortable and
better designed goalie skate that alleviates at least in part the
deficiencies described above. Moreover, there is need for a goalie
skate that provides the goalie with an improved range of motion
such that the goalie can more easily assume a "butterfly" position.
There is also a need for a goalie skate boot in which the toe
portion is integrally formed with the medial and lateral sides of
the boot in order to eliminate the traditional toe cap.
SUMMARY OF THE INVENTION
[0007] A first aspect of the invention relates to a goalie skate
with a skate boot comprising an outer shell that is thermoformed
such that it comprises an ankle lateral upper edge located below
the ankle medial lateral upper edge. A second aspect of the
invention relates to a goalie skate with a skate boot having an
outer shell that is thermoformed such that it comprises an
integrated toe portion, thereby eliminating the traditional toe
cap.
[0008] As embodied and broadly described herein, the present
invention provides a goalie skate for enclosing a human foot, the
foot having a heel, an ankle with a medial malleolus and a lateral
malleolus, medial and lateral sides, a plantar surface and toes.
The goalie skate has (a) a skate boot comprising an outer shell
made of a thermoformable material, the outer shell being
thermoformed such that it comprises: (i) a sole for facing the
plantar surface of the foot; (ii) a heel portion for receiving the
heel of the foot; (iii) medial and lateral side portions for facing
the medial and lateral sides of the foot respectively; and (iv) an
ankle portion for receiving the ankle of the foot, the ankle
portion comprising a medial side having an upper edge that is a
first distance away from the sole and a lateral side having an
upper edge that is a second distance away from the sole, the first
distance being greater than the second distance; and (b) a rigid
shell comprising a toe portion for protecting the toes and a bottom
portion for receiving an ice skate blade.
[0009] As embodied and broadly described herein, the present
invention also provides a goalie skate for enclosing a human foot,
the foot having a heel, an ankle with a medial malleolus and a
lateral malleolus, medial and lateral sides, a plantar surface and
toes. The goalie skate has a skate boot comprising an outer shell
made of a thermoformable material, the outer shell being
thermoformed such that it comprises: (a) a heel portion for
receiving the heel of the foot; (b) medial and lateral side
portions for facing the medial and lateral sides of the foot
respectively; and (c) an ankle portion for receiving the ankle of
the foot, the ankle portion comprising a medial side having a
medial upper edge and a lateral side having a medial upper edge,
the lateral upper edge being located below the medial upper edge
such that lateral outward flexion of the foot is eased when the
goalie skate is in an angled position relative to the ground.
[0010] Furthermore, the present invention relates to a goalie skate
for enclosing a human foot, the foot having a heel, an ankle with a
medial malleolus and a lateral malleolus, medial and lateral sides,
a plantar surface and toes. The goalie skate comprises (a) a skate
boot comprising an outer shell made of a thermoformable material,
the outer shell being thermoformed such that it comprises: (i) a
heel portion for receiving the heel of the foot; (ii) medial and
lateral side portions for facing the medial and lateral sides of
the foot respectively; (iii) an ankle portion for receiving the
ankle of the foot; and (iv) a toe portion for facing the toes of
the foot; and (v) a sole for facing the plantar surface of the
foot; and (b) a rigid shell comprising a base for receiving the
sole of the outer shell, a toe portion for at least partially
covering the toe portion of the outer shell and a bottom portion
for receiving an ice skate blade.
[0011] The present invention also relates to a goalie skate for
enclosing a human foot, the foot having a heel, an ankle with a
medial malleolus and a lateral malleolus, medial and lateral sides,
a plantar surface and toes. The goalie skate comprises a skate boot
comprising an outer shell made of a thermoformable material, the
outer shell being thermoformed such that it comprises: (i) a heel
portion for receiving the heel of the foot; (ii) medial and lateral
side portions for facing the medial and lateral sides of the foot
respectively; the medial and lateral side portions comprising
foldable skirt portions projecting therefrom for forming a sole for
facing the plantar surface of the foot; and (iii) an ankle portion
for receiving the ankle of the foot, the ankle portion comprising a
medial side having a medial upper edge and a lateral side having a
medial upper edge, the lateral upper edge being located below the
medial upper edge such that lateral outward flexion of the foot is
eased when the goalie skate is in an angled position relative to
the ground; and a rigid shell comprising a toe portion for
protecting the toes, a base for facing the sole of the outer shell,
medial and lateral walls and a heel portion extending upwardly from
the base, the medial and lateral walls, heel portion, toe portion
and base defining a cavity for receiving at least partially the
skate boot.
[0012] These and other aspects and features of the present
invention will now become apparent to those of ordinary skill in
the art upon review of the following description of specific
embodiments of the invention in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A detailed description of examples of implementation of the
present invention is provided hereinbelow with reference to the
following drawings, in which:
[0014] FIG. 1 is a side view of a right human foot with the
integument of the foot shown in stippled lines and the bones shown
in solid lines;
[0015] FIG. 2 is a front view of the human foot of FIG. 1;
[0016] FIG. 3 is a perspective view of a goalie skate in accordance
with a first embodiment of the present invention;
[0017] FIG. 4 is an exploded view of the goalie skate of FIG.
3.
[0018] FIG. 5 is a front plan view of the goalie skate boot of FIG.
3;
[0019] FIG. 6 is a back view of a pair of goalie skates illustrated
an upright position;
[0020] FIG. 7 is a back view of the pair of goalie skates
illustrated in an angled position;
[0021] FIG. 8 is a perspective view of a goalie skate in accordance
with a second embodiment of the present invention;
[0022] FIG. 9 an exploded view of the goalie skate of FIG. 8;
[0023] FIG. 10 is a perspective view of a goalie skate in
accordance with a third embodiment of the present invention;
[0024] FIG. 11 an exploded view of the goalie skate of FIG. 10;
[0025] FIG. 12 is a top perspective view of an outer shell in
accordance with another embodiment;
[0026] FIG. 13 is a bottom perspective view of the outer shell of
FIG. 12; and
[0027] FIG. 14 is a perspective view of a thermoforming
apparatus.
[0028] In the drawings, embodiments of the invention are
illustrated by way of example. It is to be expressly understood
that the description and drawings are only for the purposes of
illustration and as an aid to understanding, and are not intended
to be a definition of the limits of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] To facilitate the description, any reference numerals
designating an element in one figure will designate the same
element if used in any other figures. In describing the
embodiments, specific terminology is resorted to for the sake of
clarity but the invention is not intended to be limited to the
specific terms so selected, and it is understood that each specific
term comprises all equivalents.
[0030] Shown in FIGS. 1 and 2 is a typical human foot F that has
toes T, a plantar surface PS, a medial side MS and a lateral side
LS, a heel H, an Achilles tendon AT and an ankle A having a lateral
malleolus LM and a medial malleolus MM, the lateral malleolus LM
being at a lower position than the medial malleolus MM.
[0031] Referring to FIGS. 3 to 7, a first embodiment of a goalie
skate is identified by the reference numeral 1. The goalie skate 1
has a skate boot 10 and a rigid shell 20. The rigid shell 20 has a
toe portion 21 for covering at least partially the toe portion of
the boot 10, a base 25 for receiving the bottom surface of the
skate boot 10, and a bottom portion 23 with an ice skate blade
receiving portion 27 for receiving an ice skate blade 18. The ice
skate blade receiving portion 27 may comprise a longitudinal slot
for receiving the blade 18 (see FIGS. 6 and 7). The bottom portion
23 may also comprise pedestals 29 connecting the base 25 and the
ice skate blade receiving portion 27. Moreover, the rigid shell 20
may comprise a medial wall 31, a lateral wall 33 and a heel portion
35, the walls 31, 33 and the heel portion 35 extending upwardly
from the base 25.
[0032] As seen in FIGS. 3 and 4, the heel portion 35, the walls 31,
33, the toe portion 21 and the base 25 define a cavity for
receiving at least partially the skate boot 10. The rigid shell 20
may be a cowling as illustrated in FIGS. 3, 4, 6 and 7. It is
however understood that the rigid shell may be integrally formed
with the skate boot in another embodiment.
[0033] As shown in FIG. 4, the skate boot 10 comprises an outer
shell 16 that is made of a thermoformable material. As used herein,
the expression "thermoformable material" refers to a material that
is capable of softening or fusing when heated and of hardening
again when cooled. Some non-limiting examples of different types of
thermoformable material comprise ethylene vinyl acetate (EVA) foam,
polyethylene foam, polystyrene foam, polypropylene foam and
thermoformable materials sold under the trade-marks MEGABIX.RTM.,
SURLYN.RTM., SONTARA.RTM., FORMO500.RTM., BYLON.RTM., MOSOCA.RTM.
and NYLON.RTM. 66.
[0034] The outer shell 16 is thermoformed such that it comprises a
heel portion 12 substantially cup shaped for following the contour
of the heel H, medial and lateral side portions 26, 28 for facing
the medial and lateral sides MS, LS of the foot F, respectively,
and an ankle portion 22 for receiving the ankle A. The ankle
portion 22 may have respective medial and lateral cup-shaped
depressions 36, 38 for receiving the respective medial and lateral
malleoli MM, LM. The lateral cup-shaped depression 38 is located
slightly lower than the medial cup-shaped depression 36 for
conforming to the morphology of the ankle A. Naturally, the ankle
portion 22 would not have cup-shaped depressions for receiving the
malleoli should such ankle portion does not cover such malleoli.
The ankle portion 22 may follow the rear profile of the Achilles
tendon AT.
[0035] The medial and lateral side portions 26, 28 comprise
respective skirt portions 60, 62 for forming a sole 14 for facing
the plantar surface PS. The skirt portions 60, 62 are adapted to be
folded inwardly so as to be affixed together to form the sole 14.
As shown in FIG. 4, the skirt portions 60, 62 are affixed together
via stitching 65 along a longitudinal central line. The medial and
lateral skirt portions 60, 62 may have equal widths, such that when
folded inwardly they are affixed together along a central
longitudinal axis of the outer shell 16. It should be understood,
however, that the medial and lateral skirt portions can be of
different widths, such that when they are folded inwardly, they are
affixed together along a longitudinal line that is closer to either
the medial side portion 26 or the lateral side portion 28.
[0036] It should be understood that the skirt portions 60, 62 may
be affixed together in a variety of different manners without
departing from the spirit of the invention, such as via adhesive,
thermal bonding, piping, zipper, staples and a projection/groove
arrangement. Alternatively, the medial and lateral skirt portions
60, 62 could be affixed together via interlocking components that
fit together in order to affix the two skirt portions together. For
example, one of the skirt portions can include an arrangement of
grooves, and the other skirt portion can include an arrangement of
corresponding projections that are able to interlock with the
grooves. As such, by interlocking the corresponding grooves and
projections, the medial and lateral skirt portions can be affixed
together.
[0037] The skate boot 10 may further comprise an inner lining 54
having a surface intended for contact with the heel H, the ankle A
and the lateral and medial sides LS, MS and a footbed 64 adapted to
be inserted within this skate boot. The inner lining 54 may be
glued and/or stitched to the inner surface of the thermoformed
shell 16. The footbed 64 has a sole portion 66 for receiving the
plantar surface PS of the foot F, and a padding wall 68 that
surrounds the heel H and faces the medial side MS and lateral side
LS. The footbed 64 can be inserted into the thermoformed shell 16
in order to sit upon the sole 14 formed either by the two foldable
skirt portions 60, 62, or against a sole that is a separate
component.
[0038] The skate boot 10 may also comprise a tongue 24, a toe cap
30 and two narrow bands 58 that are secured to the upper portion of
each of side portions 26, 28. The narrow bands 58 are made of
fabric, textile or leather. In an alternative embodiment, a single
continuous band that covers the upper portion of each of side
portions 26, 28 and wraps around the rear of the ankle portion 22
can be used instead of two distinct bands 58. Apertures 59 are
punched through the narrow bands 58, the thermoformed shell 16 and
the inner lining 54. Once punched, the apertures 59 are reinforced
by metallic rivets 61 or any suitable means as is well known in the
art of footwear construction. The tongue 24 and toe cap 30 may be
affixed to the thermoformed shell 16. In a non-limiting embodiment,
the toe cap 30 and the tongue 24 are pre-assembled prior to
installation to thermoformed shell 16. The tongue 24 is affixed to
the toe cap 30 and extends upwardly and rearwardly from the toe cap
30 for covering the forefoot of the foot F. The frontal edge of the
tongue 24 can be sewn directly to the toe cap 30 or can be fixed in
an alternative manner known in the art. The toe cap 30 can be
secured to the thermoformed shell 16 by sewing both sides of toe
cap 30 to each of side portions 26, 28.
[0039] In a non-limiting embodiment, the thermoformed shell 16 is
made of a single integral component. However, it should be
understood that the thermoformed shell 16 could also be made of
multiple sections without departing from the spirit of the
invention. For example, the thermoformed shell 16 could be made
from separate medial and lateral side portions that are affixed
together to form a shell having the three-dimensional shape shown
in FIG. 4. In a non-limiting example of implementation, the
thermoformed shell 16 is made of a composite sheet comprising a
layer of thermoformable foam.
[0040] In an embodiment not shown in the drawings, the skate boot
10 may have a rigid ankle support which is positioned between the
thermoformed shell 16 and the inner lining 54. The rigid ankle
support is adapted for providing more support and rigidity in the
general ankle area. It should be understood that in the cases where
the thermoformed shell 16 is rigid enough to support the ankle A,
there is no need to include a rigid ankle support.
[0041] Referring to FIGS. 3 to 7, the ankle portion 22 of the outer
shell 16 comprises a medial side 32 having an upper edge 40 and a
lateral side 34 having an upper edge 42. As best shown in FIG. 5,
the upper edge 40 is a first distance D1 away from the sole 14, and
the upper edge 42 is a second distance D2 away from the sole 14,
the distance D1 being greater than the distance D2. The medial and
lateral sides 32, 34 have therefore different heights since the
lateral wall 34 does not extend as high up as the medial wall 32.
In other words, the lateral upper edge 42 is located below the
medial upper edge 40, the difference of height being identified as
.DELTA.D. Note that the skate boot 10 shown in FIGS. 3 to 5 is for
a right foot. In a non-limiting embodiment, the difference of
height .DELTA.D may be between 5 to 10 mm. In an alternative
non-limiting embodiment, the difference of height .DELTA.D may be
between 10 to 20 mm.
[0042] It is understood that the outer shell 16 and the inner
lining 54 may have medial and lateral sides of corresponding
different heights such that the skate boot 10, once assembled, has
also medial and lateral sides of different heights as illustrated
in FIGS. 3, 5, 6 and 7. The medial and lateral sides 32, 34 may
cover the malleoli as illustrated herein; however, it is also
understood that the medial and lateral sides may have respective
medial and lateral upper edges that are located just below the
medial and lateral malleoli respectively.
[0043] FIG. 6 is a back view of a pair of goalie skates illustrated
in an upright position. As shown in that figure, the upper edges 40
of the medial walls 32 are higher in relation to the ground 100
than the upper edges 42 of the lateral walls 34. Shown in FIG. 7,
is the same pair of goalie skates positioned in an angled position,
wherein the blades 18 are positioned at an oblique angle .theta. in
relation to the ground 100. By having a goalie skate boot that has
the lateral upper edge 42 located below the medial upper edge 40,
the lateral outward flexion of the foot is then eased when the
goalie skate is in the angled position shown in FIG. 7.
[0044] FIGS. 8 and 9 show a second embodiment of a goalie skate 100
wherein the skate boot 110 has an outer shell 116 that is made of a
thermoformable material and is thermoformed such that it comprises
a heel portion 112 substantially cup shaped for following the
contour of the heel H, medial and lateral side portions 126, 128
for facing the medial and lateral sides MS, LS of the foot F,
respectively, an ankle portion 122 for receiving the ankle A, the
ankle portion 122 comprising medial and lateral upper edges 140,
142, and a toe portion 130 facing the toes T of the foot F. Hence,
because outer shell 116 comprises an integrated toe portion 130
facing the toes T, there is no need for a separate toe cap 30 that
is secured to the thermoformed shell 16 as illustrated in FIG.
4.
[0045] The ankle portion 122 may have respective medial and lateral
cup-shaped depressions 136, 138 for receiving the respective medial
and lateral malleoli MM, LM. The lateral cup-shaped depression 138
is located slightly lower than the medial cup-shaped depression 136
for conforming to the morphology of the ankle A.
[0046] Moreover, as for the outer shell 16, the lateral upper edge
142 of the outer shell 116 is located below the medial upper edge
140, the difference of height being identified as .DELTA.D. Note
that the skate boot 110 is for a right foot. In a non-limiting
embodiment, the difference of height .DELTA.D may be between 5 to
10 mm. In an alternative non-limiting embodiment, the difference of
height .DELTA.D may be between 10 to 20 mm. Again, by having the
lateral upper edge 142 located below the medial upper edge 140, the
lateral outward flexion of the foot is then eased when the goalie
skate 100 is in the angled position.
[0047] FIGS. 10 and 11 show a third embodiment of a goalie skate
200 wherein the skate boot 210 is identical to the skate boot 110
and wherein the components are designated by the same reference
numerals. The only difference resides in the construction of the
outer shell 216 in which the ankle portion 222 comprises medial and
lateral upper edges 240, 242 that are at the same height. Moreover,
the skate boot 210 has an inner lining 254 having medial and
lateral upper edges that are also at the same height.
[0048] FIGS. 12 and 13 show another outer shell 316 that is
thermoformed such that it comprises a heel portion 312
substantially cup shaped for following the contour of the heel H,
medial and lateral side portions 326, 328 for facing the medial and
lateral sides MS, LS of the foot F, respectively, an ankle portion
322 for receiving the ankle A, and a toe portion 330 facing the
toes T of the foot F. Again, because the outer shell 316 comprises
an integrated toe portion 330 facing the toes T, there is no need
for a separate toe cap 30 that is secured to the thermoformed shell
16 as illustrated in FIG. 4. A sole 314 is integrally formed with
one of the medial side portions (the medial side portion 326 as
shown in FIGS. 12 and 13) and the medial and lateral side portions
326, 328 may be affixed together at the rear and along the sole
314.
[0049] In order to manufacture the outer shell 16, a pre-cut sheet
of thermoformable material may be inserted in the cavity of one of
a male-female mold. The male and female portions of the molds
define the inner and outer surfaces of outer shell 16
respectively.
[0050] The pre-cut sheet is aligned and temporarily secured to one
of the mold portions using any suitable means to accurately
position the pre-cut sheet within the mold and maintain same in
position when the mold is closed. Once the mold is closed over the
pre-cut sheet, the mold is heated up to the thermoforming
temperature of the pre-cut sheet and male and female portions are
pressed against the pre-cut sheet.
[0051] The pre-cut sheet of thermoformable material may be a
composite sheet comprising layers of different thermoformable
materials. It is understood that the pre-cut sheet can be
thermoformed with a pre-cut sheet of the inner lining 54, instead
of securing the inner lining 54 to outer shell 16 after the
thermoforming operation. Naturally, the material of the inner
lining 54 must be selected from materials that may sustain the
thermoforming temperature of the outer shell 16.
[0052] In a preferred embodiment of the invention, heat and
pressure are applied simultaneously for a period of 15 seconds to 2
minutes after which the mold is allowed to cool down so that the
pre-cut sheet will set to the three-dimensional shape defined by
the male and female portions of the mold. Preferably, heat and
pressure are applied simultaneously for a period of 45 seconds to 1
minute. The applied heat is generally between 250.degree. F. and
350.degree. F., with the preferred temperature being approximately
325.degree. F. The applied pressure is generally between 75 psi and
150 psi, with the preferred pressure being approximately 125 psi.
It is understood that the amount of time, temperature and pressure
may be different if a cooled mold is used.
[0053] Instead of using a male-female mold, an apparatus 72 as
shown in FIG. 14 may be used for thermoforming a pre-cut sheet of
thermoformable material into the shape of the outer shells 16, 116,
226, 326. The pre-cut sheet of thermoformable material may be a
composite sheet comprising layers of different thermoformable
materials. The sheet may be made of thermoforming materials such as
those sold under the trade-mark MEGABIX.RTM. (a core of extruded
SURLYN.RTM., a backing of SONTARA.RTM. and a hot melt coating;
thickness of 0.95 mm), FORMO500.RTM. (non woven polyester with a
core of extruded polyolefinic, stiffening layers of synthetic latex
on each side and an ethylene vinyl acetate hot melt adhesive on one
side; thickness of 1.50 mm), BYLON.RTM. (a nylon multifilament with
a backing of black saturated needle punched polyester nonwoven and
a face coating of non-fray urethane) and MOSOCA.RTM. (NYLON.RTM. 66
with a core of SURLYN.RTM. and a PU coating). The composite sheet
may also be made of a first sheet of polyethylene high density
(HDPE) foam; a second sheet of thermoplastic; and a third composite
sheet made of a first layer of cotton, a second layer of surlyn
fibers, a third layer of a mesh of nylon fibers and a coating.
[0054] The apparatus 72 comprises a supporting frame 74 having an
outer shell traverse and two pillars 76A and 76B. The two pillars
76A and 76B are joined together at mid-height by a ledge 78 that
contains a control panel (not shown) with control buttons (not
shown) for enabling an operator to control the apparatus 72. In the
specific embodiment shown, the ledge 78 surrounds a last 80 that is
supported by a movable support 82. The movable support 82 is a
hydraulic or pneumatic piston cylinder 84 that is movable up and
down in a vertical direction, as indicated by arrow A. It should be
understood that lasts 80 of different shapes and sizes can be
installed on apparatus 72, in order to manufacture outer shells of
different shapes and sizes.
[0055] The apparatus 72 further comprises a pair of clamps 86A, 86B
that are mounted to the outer shell traverse and positioned
directly above last 80. Clamps 86A, 86B are adapted to open and
close, as indicated by arrows B in order to clamp around the last
80. The clamps 86A, 86B comprise pressure pads 88 for receiving the
sheet of thermoformable material. In addition, each of the clamps
86A, 86B comprises a bladder (not shown) having an inflated
membrane and a fluid pressure delivery circuit (not shown) for
causing the membrane to inflate, such that it is able to surround
the last 80 during use.
[0056] In operation, the sheet of thermoformable material is placed
on the last 80 and is accurately positioned and secured in place
via the use of clips (not shown). Once the sheet is securely in
place, the operator activates the apparatus 72 which causes the
piston-cylinder 84, and therefore the last 80, to raise up between
the two open clamps 86A, 86B. When the last 80 reaches the pressure
pads 88, the piston-cylinder 84 reaches a set value and stops. It
should be understood that in an alternative embodiment, the last 80
can remain stationary, and the clamps 86A, 86B can be connected to
piston-cylinders for lowering the clamps 86A, 86B around the last
80.
[0057] Once the last 80 is positioned between clamps 86A, 86B, the
clamps 86A, 86B begin to close thereby causing the pressure pads 88
to apply an initial pressure to the sheet of thermoformable
material situated on the last 80. When the clamps 86A, 86B are
completely closed, the bladders are then inflated by air or liquid
injection, which forces the flexible membranes of the bladders to
encircle the sheet around the last 80 and apply pressure thereto.
Once the pressure within the bladders has reached a set value
wherein the bladder membranes apply an even pressure to the sheet,
the pressure is maintained for a certain amount of time, and is
then released.
[0058] In a non-limiting example of implementation, a pressure
between 30 psi and 120 psi is maintained around the last for
approximately 1 to 2 minutes. In addition to the pressure, heat is
also applied to the sheet of thermoformable material. The applied
heat is generally between 250.degree. F. and 550.degree. F., with
the preferred temperature being approximately 450.degree. F. Once
heated, the sheet becomes malleable and, as such, is able to
acquire the three-dimensional shape applied to it by the last 80.
The clamps 86A, 86B are afterwards opened up and the last 80 is
lowered by the piston cylinder 84 to its original position.
[0059] By utilizing different grades of thermoformable material,
different thermoformable materials or the same material with
different density, the designers are able to vary the mechanical
properties of the outer shells 16, 116, 216, 316.
[0060] A last may be inserted into the inside cavity of the outer
shell in order to complete the construction of the boot. The last
enables the outer shell to maintain its shape when skirt portions
60, 62 are folded and affixed together. As shown in FIG. 4, the
skirt portions 60, 62 may be affixed together via stitching 65
along a longitudinal central line. As indicated previously, the
skirt portions 60, 62 may be affixed together in a variety of
different manners without departing from the spirit of the
invention, such as via adhesive, thermal bonding, piping, zipper
staples and a projection/groove arrangement. Once the skirt
portions 60, 62 are firmly attached together and the boot has
acquired its final shape, a light sanding of the folded skirt
portions 60, 62 may be performed to partially even the lower
surface of the boot and provide a flat surface on which the rigid
shell 20 can be glued or nailed.
[0061] Alternatively, an insole may be positioned inside the skirt
portions 60, 62. It is understood that the insole is an optional
component and may not be required if the rigidity of the skirt
portions 60, 62 is sufficient. Once the assembly is completed, the
boot is placed upside down into a lasting machine. Glue is first
applied to the bottom surface of the insole along its periphery.
Skirt portions 60, 62 are then folded over the last onto the bottom
surface of the insole. Once folded, skirt portions 60, 62 are
bonded to the insole by the glue that was previously laid on the
bottom surface of the insole. The skirt portions 60, 62 are further
nailed, stitched, or tacked all around the insole to provide the
necessary mechanical grip and allow the glue to properly set
between the skirt portions 60, 62 and the insole. Once the skirt
portions 60, 62 are firmly attached to the insole and the boot has
acquired its final shape, a light sanding of the folded skirt
portions 60, 62 may be performed to partially even the lower
surface of the boot and provide a flat surface on which the rigid
shell 20 can be glued or nailed.
[0062] The above description of embodiments should not be
interpreted in a limiting manner since other variations,
modifications and refinements are possible within the spirit and
scope of the present invention. The scope of the invention is
defined in the appended claims and their equivalents.
* * * * *